Wipe Packet Forming Assembly with Vertical Transfer Bands
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Solution Overview
Problem
Existing systems for producing and packaging multilayer packets of disposable wet wipes face issues with production speed, synchronization, and deformation of wipes due to alternating motion in tampers, leading to irregular stacking, material waste, and increased costs.
Innovation Solution
A forming assembly with continuous vertical translation motion using synchronized bands with blades and moving indices to transfer wipes from the main line to the secondary line without impact, ensuring precise and orderly production without deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If alternating motion tampers are used to transfer wipes, then counting and ejection speed can be increased, but production speed is compromised due to inertia and motion reversal
Solution Approach 1:
The patent applies periodic action through the alternating motion of tampers that descend to push assemblies onto the secondary line and then ascend to receive the next assembly. This cyclic push-up motion creates regular periodic intervals for transfer operations, enabling synchronized counting and ejection while maintaining continuous production flow.
Solution Approach 2:
The patent employs dynamic motion control where tampers follow the eccentric movement of assemblies, adjusting their position and speed to match the varying height and speed of incoming wipe assemblies. This dynamic adaptation allows the system to handle different packet formats and maintain synchronization without compromising production speed.
2Reliability
If alternating motion tampers are used, then synchronization can be improved, but assemblies may fall irregularly onto the secondary line
Solution Approach 1:
The patent implements feedback control through sensors that detect the position and speed of assemblies on the main line. This information feeds back to the tamper control system, which adjusts the timing and motion of tampers to maintain precise synchronization. The feedback mechanism ensures that tampers arrive at the correct position to push assemblies onto the secondary line, preventing irregular stacking.
Solution Approach 2:
The patent introduces a secondary line as an intermediary transfer zone between the main production line and the packaging section. Assemblies are temporarily deposited on this intermediate line, allowing the system to buffer and regulate the flow. This intermediary structure decouples the synchronization requirements of different sections, improving overall manufacturing precision.
3Length of moving object
If higher groups of wipes are processed, then packet height increases, but greater force is required causing deformation
Solution Approach 1:
The patent segments the transfer operation into multiple smaller pushes rather than one large force application. Multiple tampers or sequential pushing actions divide the total required force into manageable increments, reducing the peak force applied to any single assembly and preventing deformation even when processing tall packets.
Solution Approach 2:
The patent employs cushioning elements or compliant surfaces at the contact points between tampers and assemblies. These cushioning features absorb excess force and prevent direct impact that could cause deformation. The cushioning is built into the system design beforehand, ensuring protection for all packet heights without requiring adjustment.
4Reliability
If distance between assemblies is increased to accommodate tamper motion, then production speed decreases, but synchronization is improved
Solution Approach 1:
The patent resolves the space-time conflict by utilizing the vertical dimension for tamper motion while maintaining horizontal continuity of assembly flow. Instead of increasing horizontal distance between assemblies, the system uses vertical push-up motion to transfer assemblies onto the secondary line. This dimensional change allows tight horizontal spacing (maintaining production speed) while providing sufficient space for tamper operation.
Data Source
AI summary
A forming assembly of multilayer packets of wet wipes includes: a feeding device of wipes assemblies; a forming device of packets including wipes assemblies; a packet removing device, where the forming device receives the wipes assemblies from an upper level and releases the packets at a lower level; first and second bands closed in a loop, moving along a path having a respective operating section extending vertically, including blades facing one another along the respective operating section creating housings for single wipes assemblies and defining a free space; a moving index in the free space ejecting a predetermined number of wipes assemblies onto the removing device; and a movement member advancing the index through the free space, the index including a fixed body associated with the movement member and a moving portion associated with the fixed body, allowing the index height to vary with respect to the removing device.